JP2012232524A - Method for forming colored mortar decorative layer in decorative concrete - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of forming a colored mortar decorative layer, for expressing a pattern with clear color boundary using colored mortar while preventing the colored mortar decorative layer from being removed from base concrete.SOLUTION: A mold frame including a bottom frame and a side frame is produced. Cement, sand and a pigment are blended with water of an amount that ensures thixotropy to obtain colored mortar. Partition plates for partitioning a space on the bottom frame are placed at positions along a desired pattern. The partition plates is filled with the colored mortar to form a thickness of 1 to 2 cm. After the partition plates in contact with a filled part are removed, a space between a place from which the partition plate has been removed and another partition plate or the side frame is filled with the colored mortar of different color, and this operation is repeated. Immediately after the partition plates are removed, water is removed from the colored mortar, and then the next colored mortar of different color is supplied repeatedly. After the mold frame is completely filled with the colored mortar, concrete is cast from above uncured colored mortar to arbitrary thickness. After curing, demolding is performed to obtain decorative concrete.

Description

  The present invention relates to a method for forming a color pattern with colored mortar on the surface of a concrete secondary product used for a wall surface of a building or a fence, and more particularly to a forming method for sharpening the color boundary of a colored mortar decorative layer.

The following Patent Document 1 proposes a “method for producing a concrete product having a decorative coating layer” for producing a product having a multicolored pattern on the surface of a concrete product using colored mortar.
In the manufacturing method, there is a description that a multicolor pattern film can be formed on the surface of a concrete product, and the durability of the film can be increased.

Japanese Patent Laid-Open No. 11-303302

  However, in the manufacturing method of Patent Document 1, since the mortar decorative coating layer is formed into a thin film layer by a method such as spraying, the pattern has no depth, and the boundary line between different colors is blurred and cannot be expressed clearly. There are difficulties, so it was unsuitable for expressing colored thin lines.

  Therefore, the present invention is to provide a method capable of expressing a pattern with clear color boundaries with colored mortar using many colors without peeling off the colored mortar makeup layer from the underlying concrete. Objective.

  In order to solve the above-mentioned problems, in claim 1 of the method for forming a colored mortar decorative layer in decorative concrete of the present invention, a) a mold frame comprising a flat bottom frame and a side frame surrounding it is prepared, b) Cement, sand, and pigment are mixed with water in such an amount that thixology can be obtained to obtain a colored mortar, and c) a partition plate that divides the space on the bottom frame in the mold is positioned along a desired pattern The colored mortar is filled to the inside of the partition plate to a thickness of 1 cm to 2 cm, and the partition plate in contact with the filling portion is extracted, and then the partition plate is separated from the portion where the partition plate was removed. Repeat the filling of colored mortars of different colors between the plates or side frames, and leave each colored mortar as it is immediately after extraction of each partition plate, then drain the colored mortar, and then add the colored mortar of the next different color. filling D) After the filling of the colored mortar into the mold is completed, concrete is placed in the mold to an arbitrary thickness from above the uncured colored mortar, and e) after the colored mortar and concrete are cured Demolding to obtain decorative concrete.

  The invention according to claim 2 is characterized in that, in the above invention, the amount of water mixed with which the thixologic property for the cement, sand and pigment as the raw material of the colored mortar is obtained is confirmed by flow value inspection.

  The invention according to claim 3 is characterized in that, in each of the above-mentioned inventions, the mixing ratio of cement, sand and pigment as raw materials for the colored mortar is 20 to 30 parts by weight of sand and 10. It is characterized by being 1 to 10 parts by weight.

In the present invention, since the colored mortar on the decorative surface is poured onto the back side of the colored mortar during curing and the concrete is poured, the colored mortar and the concrete are cured while shrinking at the same time, so that the colored mortar and the concrete are firmly adhered and integrated. And the peeling of the colored mortar decorative layer does not occur.
In addition, after filling the colored mortar in the partition plate and removing the partition plate, it does not lose its shape due to thixology, and each colored mortar is drained so that the other color of the color boundary of the pattern As a result, the color boundary can be clearly expressed.
Further, since the thickness of the colored mortar is as thick as 1 cm to 2 cm, even if the surface is slightly decolored due to wear, the pigment is freshly colored in the deep concave portion of the colored mortar, so that the color depth is obtained.

  In the invention described in claim 2, by confirming the amount of mixed water, the thixology can be obtained with certainty, and there is no possibility that the side surface of the colored mortar will collapse after the partition plate is removed.

  In the invention described in claim 3, after being cured and dried, the shrinkage rate becomes equal to that of concrete, so that it is possible to obtain an integrated product without delamination between the underlying concrete and the colored mortar decorative layer. It becomes.

It is a flowchart which shows the process of this invention. (A) shows a formwork, (b) is each perspective view showing a state where a partition plate is placed thereon, (c) shows each material of colored mortar, and (d) shows each material. It is each perspective view which shows the coloring mortar which mixed No., and shows the filling start into the partition plate of (e) coloring mortar. (F) is a perspective view showing the completion of filling of the colored mortar into the partition plate, (g) shows each material of the concrete, (h) shows the concrete, (re) each showing the placement of the concrete It is a perspective view. (N) shows the middle of removing the mold, and (L) is a perspective view showing a state where all the mold is removed. (A) shows a formwork, (b) shows a state in which a partition plate is assembled in a pattern, and (c) shows each longitudinal side view showing a state during filling of the colored mortar into the partition plate. is there. (D) shows the state where the first partition plate is filled with the colored mortar, (e) shows the state where the second partition plate is filled with the colored mortar, and (f) shows the third step. It is each vertical side view which shows the state which filled the coloring mortar in the partition plate. (G) is a longitudinal side view showing a state in which concrete is placed, and (H) is a longitudinal perspective view showing a state in which a formwork is removed.

Embodiments of the present invention will be described below with reference to the drawings.
FIG. 1 is a flowchart showing the steps of a method for forming a colored mortar decorative layer in decorative concrete of the present invention.

In the present invention, as shown in the flow chart, the process proceeds in the order of a mold forming process, a colored mortar mixing process, a colored mortar filling process, a concrete placing process, and a demolding process.
Finally, as shown in FIG. 4 (le), a plate-shaped or block-shaped decorative concrete on which a surface with various color patterns such as characters, characters and landscapes, complex pictorial patterns such as still life, etc. is made up. Get the product.

  First of all, in the mold forming step, a box-shaped mold comprising a flat bottom frame and a side frame surrounding it is created.

  In the next colored mortar mixing step, colored mortar is obtained by mixing the cement, river sand, and pigment of the determined composition with an amount of water capable of developing thixology.

In the subsequent colored mortar filling step, a partition plate that divides the space on the bottom frame into small portions is placed at a position along the pattern to be drawn.
And the inside of the partition plate is filled with the colored mortar to a thickness of about 1 cm to 2 cm, and after the partition plate in contact with the filling portion is extracted, the partition plate is separated from the portion where the partition plate has been extracted. Repeat filling of colored mortars of different colors between the plates or side frames.
At that time, after the partition plate is removed, it is left to drain water before the next filling.

  In the next concrete placing step, the concrete is cast to a desired thickness in the mold from above the colored mortar while the colored mortar is uncured.

In the final demolding step, after the colored mortar and concrete are cured, the mold is removed after natural drying and a certain strength.
The decorative concrete with a color pattern is obtained by the above process.

  The present invention is carried out in the above-described steps. This will be described in more detail below, taking as an example the case of obtaining a 1 m square concrete product embedded in a wall surface.

  First, in the mold forming step, as shown in FIGS. 2 (a) and 5 (a), a 15 mm-thick mold plywood with a release coating applied to one surface is cut into a square of 1 m in length and width. The bottom mold 1a is fixed to the bottom frame 1a with screws or nails, with the side frame 1b having a width of 10cm raised uniformly 8.5cm from the upper surface of the bottom frame 1a with the release coating application surface of the entire circumference facing inward. Then, a box-shaped mold 1 composed of the bottom frame 1a and the side frame 1b is produced.

Next, as shown in (c) of FIG. 2, the cement 2, sand 3, and one color, for example, a red pigment 4a, are mixed with a predetermined amount of water 5 and shown in (2) of FIG. Thus, a red colored mortar 6a having thixological properties is obtained.
Depending on the temperature and humidity of the day, the amount of water from which thixology is obtained varies.
Therefore, in the first red colored mortar 6a obtained, it is confirmed that the flow value is “0”, and the mixed water amount on the implementation day is determined. And the brown coloring mortar 6b which mixed the other brown pigment 4b with the determined amount of mixed water is obtained. The resulting brown colored mortar 6b also has thixological properties.
In this way, a red colored mortar 6a, a brown colored mortar 6b, and a blue colored mortar 6c with different red pigment 4a, brown pigment 4b, and blue pigment 4c are obtained.

As the cement 2 to be used, portland cement, silica cement, blast furnace cement, or the like can be used.
Sand is preferably river sand, and sea sand containing salt may be washed before use to reduce salt.
As the pigment 4 for coloring the mortar, an inorganic pigment having excellent weather resistance, an organic pigment capable of obtaining a large number of colors, or a pigment in which an inorganic system and an organic system are mixed can be used.
For example, in the case of inorganic pigments, white can be titanium oxide, red can be petal, yellow can be iron oxide, blue can be cobalt blue, ultramarine blue, and black can be synthetic iron oxide.
As the organic pigment, red can be used such as quinacridone red, yellow is cyindoline yellow, blue is copper phthalicyanine, and green is chlorinated copper phthalosolanine. Intermediate colors can be created by mixing the primary colors.
In addition to this, a small amount of various functional admixtures such as a polymer resin-based admixture for increasing the strength or providing a waterproof function may be added to such an extent that the thixology is not impaired.

The amount of mixed water varies depending on the temperature of the working environment, and the curing rate and drying rate also vary depending on the temperature.
For example, freezing of mortar may occur at 4 ° C or lower, and rapid curing or drying may occur at 25 ° C or higher. Therefore, it is carried out in a suitable temperature environment of 5 ° C to 25 ° C. It is preferable that the working time for filling the colored mortar 6 is sufficiently obtained.

The flow value is inspected by placing fresh colored mortar 6 mixed with water on a horizontal surface such as a glass plate into the pipe and pulling up the pipe.
When the flow value is “0”, the side of the colored mortar does not collapse when the pipe is pulled up, so that confirmation is easy.

In the next colored mortar filling step, as shown in FIG. 2 (e) and FIG. 5 (b), the height of the partition plate 7 is preferably 1 cm to 2 cm. In this example, the layer thickness is 1.5 cm. A partition plate 7 formed in a pattern is installed in the mold 1.
Then, as shown in FIG. 5C, the colored mortar 6 is filled into the partition plate 7.

As shown in FIG. 5C, when the red colored mortar 6a is filled in the middle partition plate 7a, the procedure for filling the colored mortar 6 is as shown in FIG. The partition plate 7a is extracted after about 5 minutes, and the next brown colored mortar 6b is filled including the partition plate 7a portion between the partition plate 7b and the partition plate 7b.
By pulling out the partition plate 7a, the support surface of the rising surface of the colored mortar 6a is lost, but the colored mortar 6a has thixology and does not lose its shape. For this reason, the boundary surfaces of colored mortars of different colors are not obscured and are clearly separated and repeated.

At that time, after the partition plate 7a is removed, the partition plate 7a is left for 5 minutes, and water is discharged from the red colored mortar 6a already filled before the next brown colored mortar 6b is filled.
In the present invention, the draining means that only excess water is oozed out from the lower portion of the vertical surface from which the partition plate 7a is removed, and the colored mortar becomes harder and more difficult to be deformed.
When the partition plate 7a is extracted, excess water naturally flows out from the lower portion of the filled red colored mortar 6a for a while with the initial curing of the mortar. By draining the water, the colors of the red and brown pigments mixed in the mortars 6a and 6b adjacent to the red and brown do not ooze each other, and the color boundary becomes clear.
Then, the partition plate 7b is extracted, placed outside for 5 minutes including the part of the partition plate 7b extracted from the partition plate 7c, and drained from the brown colored mortar 6b to remove the blue colored mortar. Fill 6c.

Further, the next partition plate 7c is extracted, and the yellow colored mortar 6d is filled outside the brown colored mortar 6b including the portion of the partition plate 7c extracted between the side frame 1b.
At that time, after the partition plate 7c is removed, the water is discharged from the colored mortar 6c already filled before the next colored mortar 6d is filled for 5 minutes.
As described above, the water discharge time is usually about 5 minutes, but about 10 minutes is preferable because it is delayed in winter.

  In this way, the procedure for filling the colored mortar 6 is as shown in (c) of FIG. 5 and (ii), (e), and (f) of FIG. 6, and filling the colored mortars 6a, 6b, 6c, and 6d. Each time, the partition plates 7a, 7b and 7c are sequentially and repeatedly extracted, and then the colored mortar 6b is overlaid and filled in the color portion adjacent to the extracted portion.

Next, in the concrete placing process, as shown in FIG. 3 (f) and FIG. 7 (g), as shown in FIG. The concrete 12 is placed in a 7 cm thickness in the mold.
As shown in FIG. 2G, the concrete 12 to be cast is a mixture of cement 8, sand 9 and gravel 10 in a weight ratio of 10 to 20 parts by weight of sand, gravel. It mix | blends with 10-20 weight part, mixes moderate water 11, and is obtained by stirring and mixing (shown in (h) of FIG. 3).
The timing of placement is preferably as soon as the colored mortar 6 is settled, and is up to 3 hours when the temperature is controlled in an appropriate temperature environment of 5 ° C. to 25 ° C. Otherwise, it is 1 hour in summer. The installation will be completed in about 6 hours in winter.

As the cement 8 used for this, port cement, silica cement, blast furnace cement or the like can be used.
Further, when the product has a large area and a thickness of about 15 cm, a reinforcing bar can be put into the concrete to increase the strength and prevent cracking.
Further, when the area of the product is larger, it is likely to shrink greatly and cracks easily occur, so that it is necessary to devise such as placing joints in a lattice shape beforehand.

  Finally, in the demolding step, the colored mortar 6 and the concrete 12 are cured to develop strength, and after drying, the mold 1 is turned upside down, as shown in FIG. The frame 1a and the side frame 1b were removed, and a decorative layer of 1.5 cm thick colored mortar 6 was formed on the surface of the 7 cm thick concrete 12 as shown in FIG. 4 (L) and FIG. 7 (H). A beautiful decorative concrete product can be obtained in which the color boundary is clearly expressed in a decorative pattern of 8.5 cm in total.

The obtained decorative concrete product can be used for various purposes such as sticking to the surface of walls or walls using an adhesive or the like.
When a base such as a wall surface to be attached is determined, a makeup obtained by the present invention can be obtained easily and reliably by embedding a fixing bracket in a fixed position in the concrete 12 in advance corresponding to the mounting bracket position of the base. It becomes possible to attach concrete products.

  The present invention obtains decorative concrete used for decoration of a building such as a wall of a building or a wall by making up the surface of the concrete with colored mortar, but it is used for signs, signs, figurines, etc. to which color patterns are applied. It is also possible to do.

1 Mold 1a Bottom frame 1b Side frame 2 Cement 3 Sand 4 Pigment 4a Red pigment 4b Brown pigment 4c Blue pigment 5 Water 6 Colored mortar 6a, Red colored mortar 6b, Brown colored mortar 6c, Blue colored mortar 6d Yellow colored mortar 7 Partition plate 7a, 7b, 7c Partition plate 8 Cement 9 Sand 10 Gravel 11 Water 12 Concrete

Claims (3)

Create a formwork consisting of a flat bottom frame and side frames that surround it,
Cement, sand, and pigment are mixed with water in an amount that provides thixology to obtain a colored mortar.
A partition plate that divides the space on the bottom frame in the mold is placed at a position along a desired pattern, and the colored mortar is filled to a thickness of 1 cm to 2 cm on the inside of the partition plate and touches the filled portion. After extracting the partition plate, repeatedly filling a colored mortar of a different color between the portion where the partition plate was removed and another partition plate or side frame, and leaving it as it is immediately after each partition plate is extracted. After draining each colored mortar, repeatedly filling with the next colored mortar,
After the filling of the colored mortar in the mold, the concrete is placed in an arbitrary thickness in the mold from above the uncured colored mortar,
A method for forming a colored mortar decorative layer in decorative concrete, wherein the decorative mortar is demolded after the colored mortar and concrete are cured.   The method for forming a colored mortar decorative layer in decorative concrete according to claim 1, wherein the mixing amount of water capable of obtaining thixological properties for cement, sand and pigment as a raw material of the colored mortar is confirmed by flow value inspection. .   2. The mixing ratio of cement, sand and pigment as raw materials for colored mortar is 20-30 parts by weight of sand and 0.1-10 parts by weight of pigment with respect to 10 parts by weight of cement. Or the formation method of the coloring mortar decorative layer in the decorative concrete of 2.

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